Method of packaging flock fibres

ABSTRACT

Flock textile fibres are placed in a collapsible bag having openings that are large enough to permit the escape of air but too small to permit the escape of any significant amount of fibres, the bag is partially covered with a wrapping material, and pressure is applied by a baler or other compressing device, compressing the fibres within the bag and expressing air outwardly through the openings, and strapping or wiring is wrapped around the wrapping material and secured under tension. The wrapping material may be closed at the ends to form an envelope. After shipment, the strapping or wiring may be removed and the compressed fibers are re-opened and fluffed out, after relieving the compression, by tumbling or agitating the loose fibers in air.

[4 1 Oct. 28, 1975 METHOD OF PACKAGING FLOCK FIBRES [75] Inventor: William F. Laird, Kingston, Canada [73] Assignee: Hartford Fibres Ltd., Kingston,

Canada [22] Filed: Nov. 8, 1973 [21] Appl. No.: 413,903

Primary Examiner-Travis S. McGehee [5 7] ABSTRACT Flock textile fibres are placed in a collapsible bag having openings that are large enough to permit the escape of air but too small to permit the escape of any significant amount of fibres, the bag is partially covered with a wrapping material, and pressure is applied by a baler or other compressing device, compressing [52] US. Cl. 53/24; 53/124 A; 206/835 [51] Int. Cl. B65B 13/20 the fibres the bag and expressmg [58] Field of Search 53/24 124 A thmugh the Openings and Strapping Wiring is wrapped around the wrapping material and secured [56] References Cited under tension. The wrapping material may be closed UNITED STATES PATENTS at the ends to form an envelope. 3 541 752 11/1970 Ness 53/24 After shipment, the strapping or wiring may be 3 824 758 7/1974 Han t 53:12::III 1 53/24 removed and the compressed fibers are reopened and fluffed out, after relieving the compression, by

FOREIGN PATENTS OR APPLICATIONS tumbling or agitating the loose fibers in air. 252,667 6/1964 Australia 53/24 18 Claims, 10 Drawing Figures I as US. Patent 0a. 28, 1975 Sheet 1 of2 3,914,918

METHOD OF PACKAGING FLOCK FIBRES BRIEF DESCRIPTION OF THE INVENTION This invention relates to a method of packaging for shipment a multiplicity of flock textile fibres composed of synthetic polymeric material, which fibres are of such small size that they normally lie under natural ambient conditions in the form of a fluffy mass containing substantial volumes of trapped air. Such flock fibres normally cost excessive amounts for shipment from place to place, because they occupy a volume which is disproportionate to their weight. Accordingly, for example, a truck trailer which will normally carry 30,000 to 35,000 pounds of ordinary textile staple fibres can carry no more than 15,000 to 16,000 pounds of flock fibres within the volume that can be accommodated by the trailer. Accordingly, the freight cost per pound for flock fibres is about twice the normal cost for ordinary staple fibres.

Further, the fluffy mass tends to take on moisture readily when exposed to high humidity or when the package containing the fibres is exposed to the elements. It is difficult to control its moisture content during shipment or during periods of storage outside the normally humidity-controlled flocking area.

This invention further relates to a package containing compressed flock fibres, which package can be shipped with great economy because of the increased density of the package.

DISCUSSION OF THE PRIOR ART It has been customary to ship flock fibres in 50- or 75- pound paper bags, or burlap bags unlined or lined with plastic sheeting, which bags are simply placed in the trailer of a trailer truck for shipment from the plant in which the fibres are manufactured to the plant in which they are used. Such plants are frequently quite far apart, such that shipping expenses become a significant factor in the cost and, indeed, of the ultimate feasibility of using flocked fibres at some locations. So far as I am aware, there has heretofore been no economically practical procedure or proposal which has usefully provided a relatively high-density package of flock fibres in a form in which they could be shipped economically and easily used in a flocking operation.

We are aware of prior art which discloses the baling of various objects, including foam rubber pillows as disclosed in the patent to Ness US. Pat. No. 3,541,752. However, in the Ness patent the objects dealt with are unitary foam rubber pillows which, if covered at all, have a plastic cover provided with a considerable number of large holes to provide for the escape of air. If such holes were to be used with flock fibres, the flock fibres would be found to be so tiny that they would flow out of each of the holes even while filling the bag.

Fibres have been baled before, as indicated by the patent to Van Doorn US. Pat. No. 3,733,769, but this has required a special baling apparatus including special movable wall portions for restraining the bale. Further, a special wrapping procedure is needed in the Van Doorn patent, in which the fibres must be held in a compressed condition by the baling machine in a special manner while straps are placed about the bale. This is an expensive and time-consuming procedure having no applicability to such tiny particles as flock fibres.

The patent to Thiele US. Pat. No. 3,228,166 also discloses a fibre packing process in which the fibres are pressed together in the form of a bale but here again, special handling and baling procedures are needed including the insertion of additional press plates and ultimately stapling them or otherwise fastening them together. Other procedures have been proposed, such as that in the patent to Brady US. Pat. No. 3,717,973, but these involve complicated and expensive production lines and machines.

OBJECTS OF THE INVENTION It is accordingly an object of this invention to provide a method of producingja densely packed container for carrying flock textile fibres in shipment from one place to another, with efficiency and economy. Another ob ject is to provide a flock textile fibre package having the advantages heretofore referred to. Still another object is to provide for the economical transportation and ultimate reuse of such fibres. Other objects and advantages of this invention, including its simplicity and the ease with which it may be applied to standard baling procedures and equipment, and the effectiveness it has in reducing moisture absorption by the flock fibres, will further become apparent hereinafter and in the drawings.

DRAWINGS FIG. 1 is a view in side elevation showing certain essential elements of a typical flock cutting machine, which is not per se a part of this invention;

FIG. 2 is a fragmentary sectional view in side elevation, indicating in dash lines a portion of a bag containing flock fibres, and showing in solid lines the bag after it has been compressed in accordance with this invention;

FIG. 3 is a face view of a portion of a sewn seam of the bag, looking as indicated by the arrow III appearing in FIG. 2;

FIG. 4 is a side view of a compressed bag according to this invention, provided with sheets of plastic covering material preparatory to strapping in accordance with this invention;

FIG. 5 is a view similar to FIG. 4 showing the bag and its covering plastic sheets with the straps secured;

FIG. 6 shows a finished package similar to FIG. 5, but with the ends of plastic sheeting closed and sealed;

FIG. 7 is a view in side elevation of a typical baler, showing a plurality of bags in position for baling a package containing a plurality of bags;

FIG. 8 is a view similar to FIG. 7 with the bags compressed by the baler and strapping disposed around the compressed package of bags;

FIG. 9 is a view similar to FIG. 8, showing the pack age held by the strapping and the baler opened up again, and

FIG. 10 shows a typical baled package which contains a plurality of bags.

DETAILED DESCRIPTION OF THE INVENTION Although specific terms will be used for the sake of clarity in describing specific embodiments of the invention that have been selected for illustration in the drawings, the use of such terms is not intended as a limitation of the scope of this invention, which is defined in the appended claims.

The flock fibres with which this invention is concerned may be produced in a variety of ways, but have often been produced in the prior art by a flock cutting mechanism of the sort schematically illustrated in FIG. 1, wherein a tow T composed of a plurality of synthetic polymeric filaments is cut by a cutter C producing vast numbers of tiny flock fibres F. These may typically have lengths of about 0.010 to 0.250 of an inch, and the denier of each filament from which the fibres were produced may be from about 0.75 to 5, and sometimes even lower. Accordingly, each fibre is extremely tiny in size such that when a few pounds of flock fibres are placed in a pile, they normally lie under natural ambient conditions in the form of a fluffy mass containing substantial volumes of trapped air in the spaces between the fiock fibres. Accordingly, when this fluffy mass is placed into a bag such as a 30 to 100 pound paper bag, for example, the bag contains a very substantial quantity of trapped air and this, as heretofore stated, increases the shipping cost to as much as double, or in some cases even more.

This invention also relates to other kinds of flock, including random-cut, ground or granulated flock, for example.

This invention applies to a package containing one or more compressed bags. For ease of illustration, FIGS. 26 show only one bag, while FIGS. 7-10 show a plurality of bags in a common package.

In accordance with one aspect of this invention, as indicated schematically in FIG. 2 of the drawings, the bag 10 is placed in a baler which has capacity to exert strong compressive forces as indicated by the arrows (a) and (b). The movable force may be applied upwardly or downwardly, or in both directions at the same time. Before the opposed forces are exerted on the baler, pieces of sheeting ll, 12 are placed around opposed surfaces of the bag 10, and the actuating surfaces of the baler are caused to bear against the opposed sheets 11, 12. In this manner, the bag 10 whose original proportions appear in dash lines in FIG. 2 is compressed to a smaller size, as shown in solid lines, by the operation of the baler. Any conventional and even simple baler may be used for this purpose, so long as it can exert a force in at least one direction, and oppose it either statically or dynamically, and for that reason the details of the baler itself are not shown in the drawmgs.

The bag 10 is provided with a multiplicity of openings which can let out air but retain the fibres themselves. Although these openings may be provided in the bag in any desired way, the specific embodiment shown in FIG. 2 includesa sewn seam 13 having stitching 14 (see also FIG. 3) extending through holes 15. The spaces between stitching 14 and between the layers of paper provide gaps G, and the air readily escapes as indicated by the arrow d, in FIG. 2, without permitting any significant escape of fibres.

In the course of compression of the bag 10, the bag itself may be compressed, forming wrinkles 16 in the surface of the bag, see FIG. 4.

According to the next step of the process, as illustrated in FIG. 4, straps 20 illustrated as having buckles 21, previously placed in position, are wrapped around the bag 10 and around the sheets 11 and 12, while the bag 10 is still under compression. The straps are secured in position under tension as illustrated in FIG. 5, and the ends 22 of the sheeting 11, 12 are desirably closed and sealed as illustrated in FIG. 6. In this manner, strapped containers are prepared, containing one or more compressed and crinkled bags of paper or the like, containing a compressed mass of flock fibres, each bag having end seams having tiny passages for air into and out of the bag, and a plurality of substantially flexible straps spaced apart from one another and trained around the bag or bags and secured under tension to maintain the flock fibres under compression, and a surrounding envelope of sheeting between the bag or bags and the straps and substantially completely covering the bag or bags.

In accordance with this invention, flock fibres may be transported with economy from one location to another by pressure-forming packages of the type described above, by transporting the packages from one location to the other, by releasing the compressed fibres from the pressure maintained by the strapping, and by opening up the flock by permitting air to enter into the interstices between the flock fibres for subsequent use. This air may be permitted to reenter, for example, by simply opening the bags and tumbling the flock fibres in the presence of air, either as a part of the feed system for a flocking chamber or otherwise. Other ways of accomplishing the same result will readily occur to those skilled in the art.

FIGS. 7-10 show a plurality of bags in a common package. In FIG. 7, a baler 30 having a base 31 provided with grooves 32 has upright arms 33, 33 supporting a ram 34 having grooves 35, 35. Ram 34 is actuated by a hydraulic cylinder 36 and piston 37 in the usual manner. Mechanical gears, etc., may be used instead.

In FIG. 8, the hydraulic cylinder 36 has extended the piston 37, compressing the bags 10 which have the layers of sheeting 11, 12 previously described. While the bags are compressed, straps 20 are arranged around the package at spaced locations, by threading them through opposed grooves 32, 35, as shown. They are then buckled or otherwise secured under tension, as shown in FIG. 9, and the ram 34 is then lifted out of the way, so the package can be end-sealed as shown in FIG. 10 and carried to its destination.

Although this invention has been described in connection with specific forms thereof, it will be appreciated that various modifications may be made, including the substitution of various means for permitting the escape of air from the container for the flock fibres, and including the use of balers of different types including those having ability to bale upwardly or downwardly, or in any other direction or combination of directions.

With respect to the matter of flock fibres, these may vary in length anywhere from about 0.010 to A of an inch, but the invention is of greatest advantage in the shipment of tiny flock fibres having lengths in the range from about 0.010 to about 0.250 of an inch.

The fibres may be composed of any kind of natural, cellulosic material or synthetic polymer, for example, nylon, rayon, polyester, polypropylene, acrylic fibres, wool, cotton, rayon, etc. However, the polymer is preferably one having significant resiliency such that after being deformed, it tends to return to its original shape or configuration. This is helpful in the rejuvenation of the compressed fibres, and for their return to their original shape and condition, after the compressed package has been opened up at the receiving point of the shipment, with the reintroduction of air into the spaces between the flock fibres.

While thread is used for sewing the seams in the bag,

any other device may be used which penetrates through the bag, thus providing small openings through which air, but not the fibres, may escape.

The bag itself may be composed of paper, plastic or any other flexible material not having an open weave, and must be substantially impervious to the passage of any substantial quantity of flock fibres. For example, burlap bags (lined or unlined) may be used, and perforations may be provided in linings if necessary to permit the escape of air.

With respect to the outer layer, various flexible forms of tough plastic material are preferred, such as polyethylene sheet, for example. Polyethylene sheet is flexible and easy to handle and resists rupture when impinged upon by sharp objects, such as the forks of a fork lift truck, for example. Although it is preferred to seal the ends of the plastic layers in the manner of an envelope, these may in some circumstances be left open or lightly folded. Burlap or other open materials may be used.

It is remarkable that excellent moisture control is attainable for storage and shipment, which is particularly advantageous in the case of hydrophilic fibres such as rayon, for example. Even with rayon, which normally picks up moisture from about 7% by weight to about 13-14% by weight when exposed to humid air for a few days, the use of this invention limits the moisture pickup to a maximum of about 8-10% by weight, even after extended periods of storage.

The effect of this invention in limiting moisture pickup is enhanced by using moisture-impermeable sheets l1, l2, and by sealing their ends, to provide at least a partial moisture barrier and protecting extreme exposures such as direct rainfall. But even without such a barrier, the compressive forces compacting the flock have a pronounced effect upon resistance to water pick-up.

The method of this invention has great advantage, also, in providing for stacking for handling purposes, either in a truck or in warehousing operations. Ordinary bags of flock are unstable, compressible and are prone to shifting, so that they do not provide a good base upon which to stack other bags. This has heretofore required adhering the bags together in the stack, which is expensive and time-consuming and has required the use of costly multiple-layer bags. In contrast, bales made in accordance with this invention keep their shape for stacking, do not require adhering together, and do not require costly multiple-layer bags.

Although the straps 20 are preferably composed of relatively inelastic flexible materials such as steel, plastic or the like, elastic strapping composed of strong rubber or other elastic materials may be used as well, as well as wire, cable, synthetic strapping, webbing, tape or the like, provided they have sufficient strength to maintain enough tension to keep the flock fibres under compression within the package, all of which are generically referred to herein as straps or strapping.

Various other modifications may be made in accordance with this invention, including the substitution of equivalent elements and materials for those specifically shown and described, the use of certain features inde pendently of other features, and the reversal of certain .parts with respect to others, all within the spirit and scope of this invention as defined in the appended claims.

The following is claimed:

1. In a method of packaging for shipment a multiplicity of flock textile fibres, which fibres are of such small size thatthey normally lie under natural ambient conditions as a fluffy mass containing substantial volumes of trapped air in interstices between the flock fibres, the steps which comprise:

a. placing a fluffy mass of said flock fibres in a plurality of collapsible bags, each of said bags having a plurality of openings which are so small asto inhibit the escape of any substantial amount of said fibres, but large enough to permit the escape of air;

b..stacking said bags freely upon one another to form a stacked group and placing spaced-apart layers of strong protective flexible sheet over front and back faces of said stacked group of said bags, with other areas of said bags including said small openings arranged in free and open communication with the atmosphere;

c. applying pressure in opposed directions through at least two spaced-apart layers of said protective flexible sheeting and thereby displacing at least one of said spaced-apart layers toward the other, thereby compressing the group of bags and the fibres contained within said group of bags and expressing air outwardly through the openings in said bags to the atmosphere; and

d. mechanically. securing said spaced-apart layers by wrapping a plurality of bindings, and securing said bindings around them in direct contact with both said layers of protective flexible sheeting while said bags and fibres are compressed to maintain said fibres and the bags which contain them in a compressed, compacted condition while said bindings are in contact with both said layers of flexible protective sheeting.

2. The method defined in claim 1, wherein each said bag is paper.

3. The method defined in claim 1, wherein each said bag is substantially moisture-impermeable material.

4. The method defined in claim 1, wherein each said bag is lined burlap.

5. The method defined in claim 1 wherein said protective material is a substantially moisture impermeable sheeting material.

6. The method defined in claim 1, wherein said protective material comprises spaced-apart reinforcing pieces mechanically secured in position against said bag.

7. The method defined in claim 1, wherein said protective material is a shrink film substantially conforming to the contour of the bag and providing a sealed enclosure therefor.

8. The method defined in claim 1, wherein said flock has a chemical surface coating and is free-flowing and siftable.

9. The method defined in claim 1, wherein said openings are smaller than either the cross-section or length of said fibres.

10. The method defined in claim 1, wherein said flock is composed of fibres which are longer than their cross-section, whereby said flock fibres form a mattype filter which blocks the escape of flock fibres but allows the escape of air.

11. The method defined in claim 10, wherein said openings are larger than either said cross-section or length.

12. The method defined in claim 1, wherein one said covering material is placed against the back of the 16. The method defined in claim 1 wherein step (d) is accomplished by wrapping straps around the covering material, applying tension to the straps, and securing the straps While under tension.

17. The method defined in claim 1 wherein step (d) is followed by enclosing the group of bags of compressed fibres in said covering material, and securing said covering material in the form of an enclosure about said group of bags.

18. The method defined in claim 1, wherein said bag openings are formed by gaps between the stitches. 

1. In a method of packaging for shipment a multiplicity of flock textile fibres, which fibres are of such small size that they normally lie under natural ambient conditions as a fluffy mass containing substantial volumes of trapped air in interstices between the flock fibres, the steps which comprise: a. placing a fluffy mass of said flock fibres in a plurality of collapsible bags, each of said bags having a plurality of openings which are so small as to inhibit the escape of any substantial amount of said fibres, but large enough to permit the escape of air; b. stacking said bags freely upon one another to form a stacked group and placing spaced-apart layers of strong protective flexible sheet over front and back faces of said stacked group of said bags, with other areas of said bags including said small openings arranged in free and open communication with the atmosphere; c. applying pressure in opposed directions through at least two spaced-apart layers of said protective flexible sheeting and thereby displacing at least one of said spaced-apart layers toward the other, thereby compressing the group of bags and the fibres contained within said group of bags and expressing air outwardly through the openings in said bags to the atmosphere; and d. mechanically securing said spaced-apart layers by wrapping a plurality of bindings, and securing said bindings around them in direct contact with both said layers of protective flexible sheeting while said bags and fibres are compressed to maintain said fibres and the bags which contain them in a compressed, compacted condition while said bindings are in contact with both said layers of flexible protective sheeting.
 2. The method defined in claim 1, wherein each said bag is paper.
 3. The method defined in claim 1, wherein each said bag is substantially mOisture-impermeable material.
 4. The method defined in claim 1, wherein each said bag is lined burlap.
 5. The method defined in claim 1 wherein said protective material is a substantially moisture-impermeable sheeting material.
 6. The method defined in claim 1, wherein said protective material comprises spaced-apart reinforcing pieces mechanically secured in position against said bag.
 7. The method defined in claim 1, wherein said protective material is a shrink film substantially conforming to the contour of the bag and providing a sealed enclosure therefor.
 8. The method defined in claim 1, wherein said flock has a chemical surface coating and is free-flowing and siftable.
 9. The method defined in claim 1, wherein said openings are smaller than either the cross-section or length of said fibres.
 10. The method defined in claim 1, wherein said flock is composed of fibres which are longer than their cross-section, whereby said flock fibres form a mat-type filter which blocks the escape of flock fibres but allows the escape of air.
 11. The method defined in claim 10, wherein said openings are larger than either said cross-section or length.
 12. The method defined in claim 1, wherein one said covering material is placed against the back of the group of bags and the other said covering material is placed against the front of the group of bags.
 13. The method defined in claim 12 wherein both ends of the group of bags are free of any of said covering material and are in open communication with the atmosphere.
 14. The method defined in claim 1 wherein the application of pressure in step (c) is accomplished by hydraulic force.
 15. The method defined in claim 1 where the application of pressure in step (c) is accomplished by mechanical force.
 16. The method defined in claim 1 wherein step (d) is accomplished by wrapping straps around the covering material, applying tension to the straps, and securing the straps while under tension.
 17. The method defined in claim 1 wherein step (d) is followed by enclosing the group of bags of compressed fibres in said covering material, and securing said covering material in the form of an enclosure about said group of bags.
 18. The method defined in claim 1, wherein said bag openings are formed by gaps between the stitches. 